Method of forming a package

ABSTRACT

A package includes a container formed to include an open mouth arranged to open into an interior product-storage region and a closure arranged to close the open mouth when the closure is coupled to the container.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 62/079,131, filed Nov. 13, 2014, which is expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to package, and particularly to a package including a container and a closure for the container. More particularly, the present disclosure relates to a method of forming a package.

SUMMARY

According to the present disclosure, a package includes a container formed to include an open mouth arranged to open into an interior product-storage region and a closure arranged to close the open mouth when the closure is coupled to the container.

In illustrative embodiments, a package is formed using a package-forming process. The package-forming process begins with providing an open vessel including a container and a sheet-support ring coupled to a brim of the container. The open vessel is then filled with food products. A package is established when a membrane sheet is coupled permanently to the sheet-support ring and temporarily to the brim of the container after the container has been filled.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:

FIG. 1 is a perspective view of a sealed packaged in accordance with the present disclosure showing that the sealed package includes a container formed to include an interior product-storage region therein and a closure coupled to the container to close an open mouth formed in the container and arranged to open into the interior product-storage region;

FIG. 2 is an exploded assembly view and diagrammatic view of the package of FIG. 1 showing that the package includes, from top to bottom, the container including an upwardly facing brim, a sheet-support ring, and a membrane sheet and suggesting that the a sealing head including an outer sealing ring and an inner sealing ring is used in the factory to couple an outer seal band included in the membrane sheet to the sheet-support ring and an inner seal band included in the membrane sheet to the upwardly facing brim of the container to establish the sealed package of FIG. 1;

FIG. 3 is a plan view and diagrammatic view of the membrane sheet of FIGS. 1 and 2 showing that the membrane sheet includes, from inside to outside, a center portion arranged to close the open mouth formed in the container when the membrane sheet is coupled to the sheet-support ring, the inner seal band configured to couple temporarily to the upwardly facing brim included in the container, and the outer seal band configured to couple permanently to the sheet-support ring;

FIG. 4 is a partial perspective view of an open vessel included in the package of FIGS. 1 and 2 showing that the open vessel includes the container and the sheet-support ring and that the sheet-support ring is coupled to the container prior to coupling the membrane sheet to both the sheet-support ring and the container;

FIG. 5 is a diagrammatic view of a package-forming process in accordance with the present disclosure showing that the process includes the steps of providing an open vessel as shown in FIG. 4, providing a membrane sheet as shown in FIG. 3, filling the open vessel in a factory, locating the center portion of the membrane sheet over the mouth of the container, the inner seal band over the upwardly facing brim, and the outer seal band over the sheet-support ring, coupling the outer seal band to the sheet-support ring using the sealing head, optionally cleaning the upwardly facing brim of the container, and coupling the inner seal band to the upwardly facing brim using the sealing head to establish the sealed package of FIG. 1;

FIG. 5A is a diagrammatic view of the providing the open vessel step showing that the step includes the steps of providing the container, providing the sheet-support ring, and mating the sheet support ring mates temporarily in snapping relation with the brim of the container to establish the open vessel;

FIG. 6 is a perspective view of a pair of open vessels showing a first open vessel being inserted through a mouth of a second open vessel into the product-storage region of the second open vessel to establish a stack of open vessels as suggested in FIG. 7

FIG. 7 is a perspective view of a stack of open vessels showing that the stack of open vessels minimizes an amount of storage spaced needed to store multiple open vessels prior to filling in the factory;

FIG. 8 is a sectional view taken along line 8-8 of FIG. 1; and

FIG. 9 is an enlarged portion taken from the circled region of FIG. 8 showing the membrane sheet coupled to the sheet-support ring and the upwardly facing brim of the container.

DETAILED DESCRIPTION

A sealed package 10 in accordance with the present disclosure is shown in FIG. 1. Sealed package 10 is formed according to a package-forming process 100 as shown in FIG. 5. Package-forming process 100 uses an open vessel 12 including a container 14 and a sheet-support ring 16 coupled to the container 14 and a membrane sheet 18 to establish sealed package 10. Open vessel 12 is filled with products, and then, membrane sheet 18 is coupled by a sealing head 20 to sheet-support ring 16 and container 14 to establish sealed package 10.

Package 10 includes membrane sheet 18, sheet-support ring 16, and container 14 as shown in FIG. 2. Prior to sealing, sheet-support ring 16 is coupled to container 14 to establish open vessel 12 and membrane sheet 18 is separate from open vessel 12. After sealing, sheet-support ring 16 and membrane sheet 18 cooperate to establish a closure 22 which is coupled to container 14 by a temporary bond 18T between membrane sheet 18 and container 14 and a permanent bond 18P between membrane sheet 18 and sheet-support ring 16.

Container 14 includes a bowl 24 and an upwardly facing brim 26 as shown, for example, in FIG. 2. Bowl 24 is formed to include an interior product-storage region 28 therein. Upwardly facing brim 26 defines an open mouth 30 arranged to open into interior product-storage region 28. Upwardly facing brim 26 includes an upper surface 26S which is configured to mate with membrane sheet 18 and form temporary bond 18T as suggested in FIG. 9. U.S. Pat. App. Pub. No. 2013/0092759 published on Apr. 18, 2013, U.S. Pat. App. Pub. No. 2012/0211497 published on Aug. 23, 2012, U.S. Pat. App. Pub. No. 2013/0047559 published on Feb. 28, 2013, U.S. Pat. App. Pub. No. 2014/0215974 published on Aug. 7, 2014, U.S. Pat. App. Pub. No. 2013/0104505 published on May 2, 2013, U.S. Pat. App. Pub. No. 2014/0326735 published on Nov. 6, 2014, U.S. Pat. App. Pub. No. 2015/0203263 published Jul. 23, 2015, and U.S. patent application Ser. No. 14/882,263 filed Oct. 13, 2015 are hereby incorporated by reference in their entirety for disclosure relating to containers.

Sheet-support ring 16 includes an outer surface 16S which is configured to mate with membrane sheet 18 to form a permanent bond 18P therebetween as suggested in FIG. 9. In one example, sheet-support ring 16 includes a lid-retention lug 34 configured to engage temporarily in snapping relation with a portion of brim 26. Lid-retention lug 34 is located in spaced-apart relation to a lower end 36 of sheet-support ring 16 and be located between upper surface 26S and lower end 36. U.S. Pat. App. Pub. No. 2013/0092759 published on Apr. 18, 2013, U.S. Pat. App. Pub. No. 2012/0211497 published on Aug. 23, 2012, U.S. Pat. App. Pub. No. 2013/0047559 published on Feb. 28, 2013, U.S. Pat. App. Pub. No. 2014/0326735 published on Nov. 6, 2014, U.S. Pat. App. Pub. No. 2015/0203263 published Jul. 23, 2015, and U.S. patent application Ser. No. 14/882,263 filed Oct. 13, 2015 are hereby incorporated by reference in their entirety for disclosure relating to sheet-support rings.

Membrane sheet 18 includes a center portion 18A, an inner seal band 18B, and an outer seal band 18C as shown in FIGS. 3 and 9. Center portion 18A is arranged to close open mouth 30 when membrane sheet 18 is coupled to sheet-support ring 16 and upwardly facing brim 26. Inner seal band 18B is configured to couple temporarily to upper surface 26S of upwardly facing brim 26 included in container 14. Outer seal band 18C is configured to couple permanently to outer surface 16S of sheet-support ring 16 as shown in FIG. 9. U.S. Pat. App. Pub. No. 2013/0092759 published on Apr. 18, 2013, U.S. Pat. App. Pub. No. 2012/0211497 published on Aug. 23, 2012, U.S. Pat. App. Pub. No. 2013/0047559 published on Feb. 28, 2013, U.S. Pat. App. Pub. No. 2014/0215974 published on Aug. 7, 2014, U.S. Pat. App. Pub. No. 2013/0104505 published on May 2, 2013, U.S. Pat. App. Pub. No. 2014/0326735 published on Nov. 6, 2014, U.S. Pat. App. Pub. No. 2015/0203263 published Jul. 23, 2015, and U.S. patent application Ser. No. 14/882,263 filed Oct. 13, 2015 are hereby incorporated by reference in their entirety for disclosure relating to membrane sheets and coupling of membrane sheets to sheet-support rings.

In one example, outer surface 16S of sheet-support ring 16 is arranged to extend downwardly away from inner seal band 18B of membrane sheet 18. Downwardly extending outer seal surface 16S minimizes shear stress experienced by outer seal band 18C during separation of closure 22 from container 14 the first time. During removal of closure 22 from container 14 the first time, temporary bond 18T resists upward movement of closure 22. As temporary bond 18T is overcome, temporary bond 18T exerts a force on permanent bond 18P. Downwardly extending outer seal surface 16S causes a substantial portion of the force to be transferred to sheet-support ring 16 in the form of compressive forces rather than as a shearing force. As a result, temporary bond 18P is maintained and damage to outer seal band 18C at permanent bond 18P is minimized.

In one illustrative example, membrane sheet 18 is made from a polyolefin material. Polyolefin materials include polypropylene, polyethylene, blends thereof, or any other suitable alternative. Membrane sheet 18 may also be made from a multi-layer film. One or more of the layers may be an oxygen barrier and a tie layer. The oxygen barrier, for example, may be ethylene vinyl alcohol (EVOH) or any other suitable alternative. Container 14 and sheet-support 16 are also made from polyolefin materials including, for example, polypropylene, polyethylene, blends thereof, or any other suitable alternative. As a result of both membrane sheet 18, container 14, and sheet-support ring 16 being formed from polyolefin, permanent bond 18P and temporary bond 18T may be chemical bonds established as a result of applying heat which causes melting and intermingling of the polyolefin materials of each.

Sealed package 10 is formed by package-forming process 100 as shown in FIG. 5. Package-forming process 100 begins with a providing operation 102 in which open vessel 12 is provided. Package-forming process 100 also includes a providing operation 104 in which membrane sheet 18 is provided. In one example, membrane sheet 18 may be provided as a separate membrane sheet. In another example, membrane sheet 18 may be included in a carrier sheet that includes other membrane sheets and scrap material.

Providing operation 102 includes the operations of providing 102A container 14, providing 102B sheet-support ring 16, and coupling 102C sheet-support ring to container 14 to establish open vessel 12 as shown in FIG. 5A. In one example, sheet-support ring 14 mates temporarily in snapping relation with a portion of brim 26 during coupling operation 102C. In one example, providing operation 102 may occur in a different facility from providing operation 104 and coupling operation 106 or in the same facility. In one example, container 14 is formed in a thermoforming process during providing operation 102A.

After providing operations 102, 104 are complete, package-forming process 100 proceeds to a filling operation 106 as shown in FIG. 5. During filling operation 106, food products or other items are placed in interior product-storage region 28 formed in container 14 through open mouth 30 formed in container 14. In some instances, portions of food products may be dropped on upper surface 26S of upwardly facing brim 26 included in container 14.

Package-forming process 100 then proceeds to a locating operation 108 as shown in FIG. 5. During locating operation 108, membrane sheet 18 is located above open vessel 12 after filling operation 106 is complete. Locating operation 108 causes membrane sheet 18 to be located such that sealing head 20 causes membrane sheet 18 to be coupled to both upwardly facing brim 26 and sheet-support ring 16. During the locating operation, membrane sheet 18 may be located relative to open vessel 12 either individually or as part of the carrier sheet with scrap and other membrane sheets.

Package-forming process 100 then proceeds to a coupling operation 110 as shown in FIG. 5. During coupling operation 110, outer seal band 18C of membrane sheet 18 is coupled to outer surface 16S of sheet-support ring 16 by permanent bond 18P. In one example, permanent bond 18P is established by an outer sealing ring 20A included in sealing head 20. In one example, permanent bond 18P is a heat seal established when outer sealing ring 20A provides heat to outer seal band 18C and outer surface 16S of sheet-support ring 20A. However, any other suitable alternatives and combinations may be used to couple outer seal band 18C to outer surface 16S of sheet-support ring 16.

Package-forming process 100 may include a cleaning operation 112 as shown in FIG. 5 in phantom. Cleaning operation 112 may be used to remove spilled food products located on upper surface 26S of upwardly facing brim 26. U.S. Pat. App. Pub. No. 2013/0047559 published on Feb. 28, 2013 and U.S. Pat. App. Pub. No. 2013/0104505 published on May 2, 2013 are hereby incorporated by reference in their entirety for disclosure relating to wiping of brims. Illustratively, cleaning operation 112 is facilitated by sheet-support ring 16 being a separate component from container 14 which allows movement of sheet-support ring 16 relative to container 14.

Package-forming process 100 proceeds to a coupling operation 114 as shown in FIG. 5. During coupling operation 114, inner seal band 18B of membrane sheet 18 is coupled to upper surface 26S of upwardly facing brim 26 by temporary bond 18T. Once membrane sheet 18 has been coupled to both sheet-support ring 16 and upwardly facing brim 26, sealed package 10 is established. In one example, temporary bond 18T is established by an inner sealing ring 20B included in sealing head 20. In one example, temporary bond 18T is a heat seal established when inner sealing ring 20B provides heat to inner seal band 18B and upper surface 26S of upwardly facing brim 26. However, any other suitable alternatives and combinations may be used to couple inner seal band 18B to upper surface 26S of upwardly facing brim 26. Inner sealing ring 20B is located a first radial distance from a central axis 11 of container 14 while outer sealing ring 20A is located a relatively greater second radial distance from the central axis of container 14.

Open vessel 12 is configured to minimize an amount of spaced used to store and transport container 14, sheet-support ring 16, and membrane sheet 18. As shown in FIG. 6, two or more open vessels 12A and 12B may be arranged to establish a stack 32 of open vessels. First open vessel 12A is arranged to extend through open mouth 30B of second open vessel 12B and into interior product-storage region of second open vessel 12B. Stack 32 minimizes space for storing containers 14A, 14B and sheet-support rings 16A, 16B as a result of each sheet-support ring 16A, 16B being coupled to each associated container 14A, 14B. Membrane sheet 18 may be stored and shipped as part of a rolled carrier sheet including several membrane sheets and scrap.

In one example, membrane sheet 18 is separated from the scrap and other membrane sheets by a cutting operation that may be included in package-forming process 100. The cutting operation may occur before, during, or after coupling operations 110, 114. The cutting operation may be performed by sealing head 20 which may include a cutter configured to separate membrane sheet 18 from the carrier sheet.

While coupling operation 110 is shown preceding coupling operation 114, it is within the scope of the present disclosure for coupling operation 110 to follow coupling operation 114. It is also within the scope of the present disclosure for coupling operations 110, 114 to occur about the same time. 

1. A process for forming a sealed package comprising the steps of providing an open vessel including a container formed to include a mouth arranged to open into an interior product-storage region of the container and a sheet-support ring, providing a membrane sheet including a center portion, an outer seal band located in spaced-apart relation to the center portion and arranged to extend around and surround the center portion, and an inner seal band located between the outer seal band and the center portion and arranged to extend around and surround the center portion, locating the membrane sheet relative to the open vessel to cause the center portion to overlie the mouth, the inner seal band to overlie and align with an upwardly facing surface of the brim, and the outer seal band to overlie and align with an outer surface of the sheet-support ring, coupling the outer seal band to the outer surface of the sheet-support ring to form a permanent bond between the outer seal band and the sheet-support ring, and coupling the inner seal band to the upwardly facing surface of the brim to establish a temporary bond between the inner seal band and the upwardly facing surface of the brim to establish a sealed package.
 2. The process of claim 1, further comprising the step of filling the open vessel with products through the mouth into the interior product-storage region after the providing the open vessel step.
 3. The process of claim 2, further comprising the step of cleaning the upwardly facing surface of the brim of any spilled products located on the upwardly facing surface of the brim during the filling step.
 4. The process of claim 3, wherein the locating step occurs after the providing the membrane sheet step and the providing the open vessel step.
 5. The process of claim 4, wherein the cleaning step occurs after the coupling the outer seal band step.
 6. The process of claim 5, wherein the cleaning step includes the steps of moving the sheet-support ring in a downward direction relative to the brim of the container and stretching the membrane sheet to cause any spilled food product trapped between the membrane sheet and the brim of the container to be wiped off the upwardly facing surface of the brim.
 7. The process of claim 1, wherein the coupling the inner seal band step occurs after the coupling the outer seal band step.
 8. The process of claim 7, wherein the providing the membrane sheet step is performed after the providing the open vessel step.
 9. The process of claim 8, further comprising the step of filling the open vessel with products through the mouth into the interior product-storage region after the providing the open vessel step.
 10. The process of claim 9, further comprising the step of cleaning the upwardly facing surface of the brim of any spilled products located on the upwardly facing surface of the brim during the filling step.
 11. The process of claim 10, wherein the locating step occurs after the providing the membrane sheet step and the providing the open vessel step and the cleaning step occurs after the coupling the outer seal band step.
 12. The process of claim 11, wherein the cleaning step includes the steps of moving the sheet-support ring in a downward direction relative to the brim of the container and stretching the membrane sheet to cause any spilled food product trapped between the membrane sheet and the brim of the container to be wiped off the upwardly facing surface of the brim.
 13. The process of claim 1, wherein the providing the open vessel step includes the steps of providing the container, providing the sheet-support ring, and coupling the sheet-support ring to the container to establish the open vessel.
 14. The process of claim 13, wherein the sheet-support ring mates temporarily in snapping relation with a portion of the brim.
 15. The process of claim 14, wherein the locating step occurs after the coupling the sheet-support ring step.
 16. A process for forming a sealed package comprising the steps of providing an open vessel including a container formed to include a mouth arranged to open into an interior product-storage region of the container and a sheet-support ring coupled to a brim of the container, providing a membrane sheet including a center portion, an outer seal band located in spaced-apart relation to the center portion, and an inner seal band located between the outer seal band and the center portion, locating the membrane sheet relative to the open vessel to cause the inner seal band to overlie and align with a portion of the container, and the outer seal band to overlie and align with a portion of the sheet-support ring, coupling the outer seal band to the portion of the sheet-support ring to form a permanent bond between the outer seal band and the sheet-support ring, and coupling the inner seal band to the portion of the container to establish a temporary bond between the inner seal band and the container to establish a sealed package.
 17. The process of claim 16, further comprising the steps of filling the open vessel with products through the mouth into the interior product-storage region after the providing the open vessel step and before the locating step and cleaning an upwardly facing surface of the brim of any spilled products located on the upwardly facing surface of the brim during the filling step.
 18. The process of claim 17, wherein the cleaning step occurs after the coupling the outer seal band step.
 19. A process for forming a sealed package comprising the steps of providing an open vessel including a container formed to include a mouth arranged to open into an interior product-storage region of the container and a sheet-support ring coupled to a brim of the container, providing a membrane sheet including a center portion, an outer seal band located in spaced-apart relation to the center portion and arranged to extend around and surround the center portion, and an inner seal band located between the outer seal band and the center portion and arranged to extend around and surround the center portion, filling the open vessel with products through the mouth into the interior product-storage region, locating the membrane sheet relative to the open vessel to cause the center portion to overlie the mouth, the inner seal band to overlie and align with an upwardly facing surface of the brim, and the outer seal band to overlie and align with an outer surface of the sheet-support ring, coupling the outer seal band to the outer surface of the sheet-support ring to form a permanent bond between the outer seal band and the sheet-support ring after the locating step, cleaning the upwardly facing surface of the brim of any spilled products located on the upwardly facing surface of the brim during the filling step after the coupling the outer seal band step, and coupling the inner seal band to the upwardly facing surface of the brim to establish a temporary bond between the inner seal band and the upwardly facing surface of the brim after the cleaning step to establish a sealed package.
 20. The process of claim 19, wherein the cleaning step includes the steps of moving the sheet-support ring in a downward direction relative to the brim of the container and stretching the inner seal band of the membrane sheet to cause any spilled food product trapped between the membrane sheet and the brim of the container to be wiped off the upwardly facing surface of the brim. 